Download SERVICE MANUAL DISHWASHER COMPACT

SERVICE MANUAL
DISHWASHER
COMPACT
Dishwasher
COMPACT
© AEG Hausgeräte GmbH
Muggenhofer Straße 135
D-90429 Nürnberg
Germany
Publ.-Nr.:
599 516 219
EN
911 328 .....
Fax +49 (0)911 323 1022
Spares Operation
Edition:
01.03
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Index
1.
Technical specifications ......................................................................................... 3
2.
3.
Installation water drainage ..................................................................................... 3
Components .......................................................................................................... 4
Capacitor ............................................................................................................... 4
Pressure switch ..................................................................................................... 4
Heater element ...................................................................................................... 4
Circulation pump .................................................................................................... 5
Drain pump ............................................................................................................ 5
NTC temperature sensor ....................................................................................... 5
Programmer ........................................................................................................... 5
Detergent dispenser .............................................................................................. 6
Rinse aid dispenser ............................................................................................... 6
Inlet valve ............................................................................................................... 6
Anti flood switch ..................................................................................................... 6
Water softening system ......................................................................................... 7
4.
5.
Position of components ................................................................................. 8 - 11
Water course scheme .......................................................................................... 12
6.
7.
Water inlet ...........................................................................................................13
Rinsing system .................................................................................................... 14
8.
9.
Strainer system .................................................................................................... 15
Level control system ............................................................................................ 16
10.
Inlet system / Overfilling/leakage protection (old version) ...................................17
Drain system ........................................................................................................ 18
11.
12.
Regeneration ....................................................................................................... 19
Thermostats ......................................................................................................... 20
13.
14.
Temperatur and safety systems .......................................................................... 21
Wirings and diagrams .................................................................................. 22 - 25
15.
Service informations ............................................................................................ 26
Spülraum ............................................................................................................. 26
Housing ................................................................................................................ 27
Panel / base plate ................................................................................................ 28
Components (lower region) ................................................................................. 29
Door components ................................................................................................ 30
Door switch .......................................................................................................... 31
Rinse aid dispenser / detergent dispenser coil .................................................... 32
Pressure switch / Anti-siphon valve / level control container ............................... 33
Thermostats / Heater element ............................................................................. 34
Programmer / switch unit / float switch / inlet valve ............................................. 35
Circulation pump / drain pump ............................................................................. 36
Softener / regeneration valve............................................................................... 37
Leakage points ............................................................................................ 38 - 39
16.
Fault tracing ................................................................................................. 40 - 42
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1.
2.
3.
1.
On/Off-button
Temperature selector
Extra drying effect
4.
5.
6.
Technical specifications
Power supply:
Heater element:
Power rating:
Fuse required:
230 V - 50 Hz
1200 W
1280 W
13 A
Height:
Width:
Depth:
460 mm
450 mm
480 mm
Water pressures:
min. 50 KPa (0,5 bar)
max. 1000 kPa (10 bar)
Capacity:
5 settings
2.
Programme selector
Indicator lamp
Salt indicator lamp
Installation water drainage
Place the discharge hose over the sink as illustrated.
It may not at any point be higher then 75 cm over the surface
which the dishwasher is standing on. If runs higher, operation of
the dishwasher might be impaired.
It is also important to ensure that the inside diameter of the hose is
not less than 13 mm at any point. If the discharge hose is too long
it can easily be cut to the right length.
Cut the hose to a suitable length, using a sharp knife.
Fit the elbow supplied onto the end of the hose.
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3. Components
Capacitor
The circulation pump is connected to a capacitor.
2,0 µF for UK
2,5 µF for Europe
Pressure Switch
The pressure switch controls the water level.
Without water, contact is closed.
Adjusting:
Turning the marked screw clockwise
Turning the marked screw anti clockwise
+ level
- level
Heating element
Power output
Resistance approx
1200 W
42 W
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Circulation Pump
The circulation pump is driven by an asynchronous
motor with an starting winding. The starting winding
ist in circuit with a 2,5 µF (Euro) capacitor. (2 µF UK)
Rating:
Main winding resistance
Starting winding resistance
60/80 W
158 Ohm
158 Ohm
Drain Pump
The drain pump is driven by a synchronous motor.
Power output
Pump rate
Main winding resistance
21/19 W.
10-12 l/min.
200 Ohm
Thermostats (normally open)
45°C
closes at 41°C
opens at 33°C
55°C
closes at 50°C
opens at 42°C
65°C
closes at 61°C
opens at 53°C
Overheating protection (normally closed)
opens at 83°C
closes at 0°C
Programmer
ELBI
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Detergent dispenser
Coil resistance
3000 Ohm
Rinse aid dispenser
Rinse agency capacity
Solenoid coil resistance
140 ccm
1900 Ohm
Inlet valve
Capacity, max,
Resistance
4 l/min
4800 Ohm
Anti flood switch
If the anti flood swich in the base tray is activated, all
components are switched off except the drain pump
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Water softening system
Operation of the water softening system
When water is admitted, the inlet valve (1) opens and the
hard water flows down into the ion exchanger (5),
through which it flows and is softened before flowing
through the water inlet (6) and then being sprayed into
the Washing chamber.
!n the meantime, the container for the regeneration
water (2) is also filled with water.
lf the rubber plug (3) at the rear of the machine is in place
as shown in the ilustration, the machine can handle
water with a hardness of up to 20'dH. !f the rubber plug
is removed. The regeneration water volume will be
increased, and the machine can then handle water with
a hardness of up to 35°dH.
During the dishwashing programme, the ion exchanger
will gradually be filled with lime and, to be able to soften
the water during the next dishwashing cycle, the ion
exchanger must be restored to its original condition.
This is done by a process known as regeneration, which
takes place according to the actual programmer diagram.
The solenoid valve (7) between the salt container and
the ion exchanger will then open, and regeneration
water will flow into the salt container (4).
A corresponding amount of water saturated with salt is
thus forced into the ion exchanger. The salt solution is
present in the ion exchanger during the last rinse, and
the small plastic balls will be recharged with sodium ions.
According to the actual programmer diagram, the inlet
valve will open and will allow about 2 litres of water to flow
through the ion exchanger to flush away the now dissolved
lime residues. The lime-rich water is then flushed
immediately out to drain, and the machine is reset and
ready for the next water fill.
The whole of this process is integrated into the
programme of a machine with water softening, and thus
takes place fully automatically.
It should also be noted that it is important to use only
coarse salt, since fine-grained salt would. form lumps.
Water which is rich in lime is said to be "hard".
Water hardness is measured in German degrees
of hardness (dH). Water up to 10dH is normally
regarded as soft, and above this value, it is
regarded as hard.
The phosphates in the detergent can handle the
hardness in soft water. But if the water is hard,
precipitations will occur, i.e. lime will be deposited
on the dishes and in the dishwasher.
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4. Position of components
Door opener
Inner door
Outer door
Door seal
Programmer / Timer
Signal lamps
Switches
(temperature)
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Housing
Coil for detergent
dispenser
Rinse-aid dispenser
Door switch
Basek rails
Coarse sieve
Interference filter
Fine strainer
Heating element
Thermostats
Base plate
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Softener
Inlet hose
Drain hose
anti-siphon valve
Regeneration valve
Reed switch
salt indicator
Inlet valve
Float switch
Pressure switch
Drain pump
Water collector
Base plate
Air chamber
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Circulation pump
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Spray arm
Sealing ring
Pump housing
Cup support
Cuttlery basket
Dish rack
Basket roller
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5.
Water Course Scheme
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6.
Water Inlet
The water flows into the regeneration dosage chamber via inlet valve, over air break, into
regeneration dosage chambers and into softener
The level control container operates the pressure switch.
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7.
Rinsing system
The function of the rinsing system is to wet the
dishes loaded into the machine.
The electric motor of the circulation pump is
delivered with the impeller fitted to it. Half the
pump casing forms part of the plastic chassis,
and the other half is bolted in position inside the
washing chamber.
This arrangement ensures, that the joint between
the two halves of the pump casing is inside the
washing chamber.
An O-ring provides the seal between the motor
assembly and the chassis.
The rating of the electric motor is 60 watts(50 Hz)
or 80 watts(60 Hz) and the pump circulates around
30 litres per minute.
The electric motor needs assistance at the instant
of starting, which is provided by a starting
capacitor.
The motor mounting is very important to the sound
level. Since the movements of the motor are a
minimum at the centre, the motor is secured to a
rubber mounting in the centre, at the rear end of
the motor.
To ensure that no vibrations will be transmitted
from the motor to the base plate, a plastic foam
spacer strip is fitted to the bottom of the chassis.
The pump casing half which is inside the washing chamber also contains the spray tube bearing with a stainless steel shaft.
The underside of the spray tube is fitted with a
seal ring to minimize leakage.
The shape and orientation of the holes in the spray
tube are such that the dishes furthest away in the
corners of the machine will also be effectively
washed.
The spray tube rotates anti-clockwise at a speed
of 10 - 20 1/min.
If the speed is too high, the dishwashing results
will be poor, and if the speed is too low, the spray
tube may stop al-together.
The pressure in the spray tube is just over 0.2 kg/
cm². The spray tube is retained by a ceramic nut
with a left-hand thread, to en-sure that the rotation
of the spray tube will not cause the nut to unscrew
itself. This means that the nut must be un-screwed
in the „wrong“ direction.
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CERAMIC NUT
SPRAY TUBE
SEAL RING
PUMP CASING HALF
MOTOR MOUNTING
O-RING
PLASTIC
TRAY
CIRCULATION PUMP
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8.
Strainer system
The strainer system is one of the systems which are most important to the performance of the
dishwasher.
The design of this system is largely decisive to whether the dishwasher will be able to perform its
most fundamental task: to wash the dishes clean.
The strainer system must trap particles of food, etc. and ensure that these particles will not be
recircu-lated and deposited back on the dishes.
Another consumer requirement is that the strainer system must be self-cleaning, so that it will not
be necessary to wash the strainers by hand every time or every other time the dish-washer is
used.
The strainer system consists of two parts which
jointly contain three different strainers, each of
which with its own particular task.
Coarse strainer
The fine strainer consists of a shaped stainless
steel plate which is perforated with 0.5 mm
diameter holes and is retained in a plastic frame.
The dishwashing water passes through this
strainer about 420 times during a normal
dishwashing programme.
The bottom of the chassis is designed in such a
manner that particles will continually be flushed
away to the coarse strainer. All particles larger
than 0.5 mm will be trapped, and the water flowing
through the strainer will thus be virtually clean.
The performance of the strainer is highly
dependent on the suction of the circulation pump
Fine strainer
being equally distributed over the entire strainer
area. If the suction is higher at any one point,
particles will be drawn through the fine strainer at
that point, and they would then disintegrate and
would be very dif-ficult to trap.
It is also very important for the plastic frame of the fine strainer to seal well against the chassis, so
that particles will not by-pass the strainer and be deposited back on the dishes.
The fine strainer also includes a small plastic boss. This is designed to prevent the build-up of pressure
and air cushions under the strainer. An air cushion under the fine strainer would otherwise prevent the
water from flowing through the fine strainer, and insufficient water would then be supplied to the circulation pump.
Particles are thus flushed continuously down into the coarse strainer, where they are retained until
the water is pumped out to drain. The coarse strainer is also designed to trap larger particles, such as
pieces of meat, toothpicks, etc.
To retain the good dishwashing properties of the machine, the consumer must empty and rinse the
strainers as soon as they show signs of clogging.
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9.
Level control system
There are two basic ways of metering the right amount of water into a dish-washer. The first is to
open the inlet valve for a certain predetermined period of time, while the other is to use some
means for measuring the water level in the machine.
The major disadvantage of the first method is that if the mains water pressure is low (which is very
common in Europe), the time allowed will be too short to fill the machine with a sufficient amount of
water. A time-controlled machine needs a water pressure of at least 1.0 - 1.5 kg/cm2. The Compact
dishwasher is level-controlled and will perform satisfactorily at mains water pressures down to 0,5 kg/
cm².
Operation of the level control system of the
Compact dishwasher
As the machine is being filled with water, the water
level in a level control container located on the
side, outside the chassis will also rise. The
container is connected to a pressure switch by
means of a hose.
As the water level in the contairier rises, the air
pressure in the hose will also increase and will
act on the pressure switch. When the pressure
has risen to a preset value, the pressure switch
will open, which will cause the inlet valve to close.
The programmer motor can now advance to the
next step.
When the drain valve then empties the machine,
it will also empty the level control container, and
the pressure switch will revert to its original
position, in preparation for the next
water fill.
The inlet hole of the level control container is below
the strainer, and the water in the level control
system is therefore always clean and filtered.
If the water level should drop for any reason while
dishwashing is in progress, the pressure switch
will close, which will interrupt the water circulation,
and the water heating possibly restart the
programmer and allow the programmer to
advance in the programme.
It is important for the machine to be perfectly level
when it is in operation, since a 5 mm difference in
level corresponds to about 1 litre of water.
between 20 - 24 mm
PRESSURE
SWITCH
LEVEL CONTROL
CONTAINER
Air pressure, p
Water level
Water pressure, p
Washing
chamber
Level control container
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Old version
Inlet system - old version
A
The inlet hose is a rubber hose with plastic cover.
The coupling nuts are made of plastic (which reduces
the risk of crossedhreads) . The inlet hose is inside the
washing chamber when the machine is delivered, and the
consumer must fit the hose when installing the machine.
He must then also decide whether the hose is to run to the
right or to the left.
B
On the machine, the inlet hose is connected to the
inlet valve (also known as solenoid valve). When the
inlet valve is energized (via the programmer) the valve will
open and water will flow into the machine. When the level
controller has sensed that the water has reached the
correct level, it will open the power supply circuit to the inlet
valvet and the valve will close.
The valve is designed to open and close slowly. It is
important to ensure that no harmful pressure surges will be
caused in the water supply mains.
D
Flooding. If a component or seal should start to leak,
the water will collect on the base plate and will
activate the floating body. To some extent, the wall along
which the water flows serves as a brake,so that spillage of
a few drops will not cause the moisture sensor to trip.
C
Overfilling protection. If the level sensor should fail to
operate and the inlet valve should remain open after
the water has reached the correct level, the water will run
across an overflow baffle down into the base plate, where
the floating body of the flooding protection system will
close the inlet valve and will prevent water damage.
Overfilling/leakage protection - old version
E
The inlet valve also incorporates a mechanical tripping
actuator. The tripping actuator is operated by a floating
body .
If water should leak into the base plate for reason,
the floating body will close the inlet valve mechanically.
The leakage protection will operate even if the
power supply cable is disconnected.
Reverse flow protection.
F
This prevents contaminated water from the dishwasher
from being drawn back into the water mains, even if a
vacuum should occur in the water mains.
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10. Drain system
The system consists of inner and outer drain hoses and a drain pump, and its function is to transport
the contaminated water as efficiently as pos-sible from the machine to the waste water system of the
buildin
The drain pump is connected to the chassis at the coarse
strainer and is sealed with an O-ring. The motor is a perOUTER DRAIN HOSE
manent-magnet motor, with the rotor.mounted inside a
plastic housing and the stator fitted to the outside of the
plastic housing. The design is such that the pump has no
traditional shaft seat which always invol-ves the risk of
leakage.
DRAIN CASING
INNER DRAIN HOSE
DRAIN PUMP
The pump performs equally well in both directions of rotation, and the direction in which it
rotates is a matter of pure chance. This also means that the pump is vir-tually proof against
jamming. If some object should enter the pump casing and jam the impellar, the motor will
immediately make a new starting attempt in the op-posite direction. Even if the impellar is
seriously jammed (e.g. by a toothpick), the motor will most probably release the impellar
within about a second. The power consumption of the motor is 23 watt, and the pump
capacity is about 10 I/min.
The internal drain hose is connected to the drain pump. To prevent the risk of the machine
being emptied by siphon action, the hose routes the drain water through a loop running up
to the top of the chassis and then through the outlet at the bot-tom of the machine, to the
outer (visible) drain hose. A hole is provided at the highest point of the inner drain hose for
venting the system.
If the drain hose is permanently connected to a water trap, it is very important that the
inside diameter of the drain system should not be less than 13 mm at any point.
New
antisiphonic device
If the end of the take-off hose
is below the level of the water
in the wash space, a siphon
effect is possible, that is, the
machine runs empty. This is
avoided by the ventilation
through the anti-siphon valve.
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11. Regeneration
The water chamber for regeneration contains 350 ml water. During regeneration, the regeneration
valve is energized. The 350 ml water runs into the salt container and mixes with the salt to form a
brine solution.
In the top of the salt container there is an opening with a small filter, from here the brine solution
enters the softener where the resins are regenerated.
The softener has 5 settings and can be adjusted to suit the degree of water hardness.
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12. Thermostats
The thermostats are pressed into the
tubular mountings in the plastic chassis.
They measure the temperature on the
outside of the plastic wall, which leads to
a certain difference between the water
temperature and the thermostat
temperature.
However, the specifications of the
thermostats take this into account. (In one
particular case, the same thermostat is
used for two different temperatures.
This is possible because the thickness of
the chassis is different at the two
thermostat mountings.
The thicker the wall, the greater the
temperature difference and the higher the
water temperature.)
Depending on the Programme selected,
the thermostats will be switched in, and
will interrupt the power supply to the heater
element via the programmer when the
water has been heated to the required
temperature.
As in the case of al! other components,
there is a certain amount of tolerance on
the nominal temperature of the
thermostats.
For the breaking temperatures, the
tolerance is ±3°. There is also a "differential", i.e. a difference between the
temperature at which the thermostat opens
the circuit and the temperature at which it
returns to the original position. This differential is 8°C.
The breaking values are adjusted to give
the following water temperatures: 45, 55,
65 and 72'C.
Colours coding of the thermostats
A = brown
B = black
C = grey
D = white
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83°C
65°C
55°C
40°C
(anti boiling protection)
(two)
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13. Temperature control and safety Systems
The dishwashing detergents available on the market today require a certain water temperature before
they can dissolve the food residues in a satisfactory way.
A temperature control system consisting of a heater element and thermostats ensures that the
water will be heated to the correct temperature.
Heater elements is 1200 watt.
In addition, the machine includes a safety system, the function of which is to protect the temperature
control System against accidental overheating.
The overheating safety system is very important. Several components and systems are involved in
different ways.
The following conditions must be satisfied before the element can be switched in:
•
•
The rnain switch must be closed, the door must be closed so that the door switch is closed,
and a Programme must have started.
The machine must contain the correct amount of water (as determined by the level control
pressure switch).
The safety system will trip if
•
•
The quantity of water is insufficient.
The water temperature has risen to about 85°C without the thermostat tripping.
In addition, two overheating protections are incorporated into the element, i.e. one at each connection
end.
These are designed so that they will burn off if the element is switched on but has no cooling water
around it.
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14. Wirings (Example DSC 14)
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Diagram (Example DSC 14)
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Wirings (Example DSC 382)
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Diagram (Example DSC 382)
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15. Service Informations
Coarse filter
The purpose of the coarse filter is to catch large objects. Make
sure that the filter is always clean.
Fine filter
It is just important to keep this filter clean. The fine filter can
easily be lifted out for cleaning when the coarse filter is removed
at first.
Spray arm
The spray arm is to be removed by unscrewing
the nut clockwise (it has a left-handed thread)
and lift of the spray arm.
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Sealing ring
To clip out he sealing ring a screwdriver gives
support.
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You need
screwdriver
Torx TX20
Housing
After removing the housing screws (lay the machine on its side) from the bottom of the
machine, the housing is unclipped front and back from the catches and can be removed.
All components from the left and right side are now accessible.
Coil for
detergent dispenser
Softener
anti-siphon valve
Rinse-aid dispenser
Pressure switch
Air chamber
Programmer / Timer
Drain pump
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Interference filter
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Thermostats
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Replacement
of the panel
Remove the screws from the
panel frame.
Remove the turning knob.
Carefully unclip the front .
Before finally opening, unclip
the lamps.
Remove the
base plate
The base plate of the machine
is held with screws on the
lower panel and at the bottom.
Lay the machine on its back
and lift off the base plate.
It contains the bosses for the
overflow water and the
flooding switch.
After removal you come to the
most important functional
components.
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Switches
(temperature)
Programmer / Timer
Thermostats
Drain pump
Air chamber
Interference filter
Circulation pump
Float switch
Regeneration valve
Softener
Inlet valve
Heating element
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Outer and inner door
They snap together and are held by plastic latches, on the under side. They can easily be unsnapped
Replacement of the
components within
the door.
After removing these screws,
the door handle and
detergend dispenser flap can
be removed from the inner
door.
After removing
the spring, the
door-opener can
be removed from
its hinges.
The seal is easily
be clipped in the
inner door frame.
Re-assembly is carried out
in the reverse order.
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To remove the inner door
Remove the lower panel and the outer door. Open the door and remove the four screws (two on
each side) securing the rack rails.
Open the door to an angle of about 130° and carefuly relese the hinge pin on the right hand side.
On the left hand side, the hinge pin is inserted in a hole without slot.
Door switch
Remove the the screws on the under side of the upper panel. Lift off the upper panel. The door switch
is easily be screwed.
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Remove this
screw to
dismount the
rinse aid
dispenser unit
The coil with tappet as support
for the detergent dispenser is
held by two screws.
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The pressure monitor
is simply screwed.
The motor capacitor is
screwed by a nut.
Anti-siphon valve
The air should be able to enter the hose from the
holder - not the other way around!
The take-off hose ventilation can be unscrewed
for cleaning when necessary, in case these rubber
parts in the interior of this
valve become dirty or
stuck
because
of
residues.
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Level control
container
(Air chamber)
Remove the srew to lift off
the level control container
for cleaning.
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Thermostats
The mounting for the thermostats is screwed at the right side of the air chamber. After its release, the
thermostats can be removed.
Heater element
After the removal of the nut and the heater clip in the sump under the fine strainer, the heater
element can be drawn forward through the chassis opening to remove..
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Programmer
The programmer is secured to the front of the
chassis by means of two screws.
Remove the programmer from the right side of the
chassis.
Switch unit
The switch unit is secured by means of screws and easily to
remove.
Float switch
The float switch is snapped out with
a small screwdriver and can be
taken out of its mounting.
After removing the protective cap,
the microswitch can be snapped
out.
Inlet valve
The inlet valve is mounted in the same place as the float switch.
After the removal of the hose, the valve can be drawn out of the
chassis with suitable pliers.
Circulation pump
After loosening the screws of the holder, the circulation pump can be taken out
of the pump chamber.
Drain pump
To dismount the drain pump, the hose clamps are released and the screws removed.
Here you can see how the hose
clamps can be re-tensioned with
wire cutting pliers.
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After removing the drain pump
the tubing-bow with seals,
fitted in the pump chamber, is
accessible.
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Softener
1 To dismount the water
softener, these attachment
screws are removed.
1
4
2 The connections on the reed
switch are removed.
3 The hose connections are
detached.
4 The large nut of the salt hol
der must be released .
5
2
5 A spanner is useful in
removing the recycling inlet
nut.
6 Now the complete unit can be
removed.
6
3
Regeneration valve
After undoing the screws of the
recycling valve, this can be
removed.
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Leakages.
Service solutions:
Take of the cover to be able to see the Container on the left hand
side.
Let the dishwasher take in water and check the level.
If the level is too high (leakage through the top of the Container)
-
adjust the pressure level switch
-
check assembling ofthe Container to tub, misaligned oring or
screw not tightened.
-
Check the Container it self (leakages between the welded base between 20 - 24 mm
and the Container walls)
Water level
Low water level.
Check ifthe Container is clogged. Clean it with hot water (after
disassembly it from the pressure level switch hose and the tub)
under a tap.
If the water level is to low, adjust the pressure level switch.
The drain pump is always running if the water
prot device is activated.
If there is a leaking point and the water prot device is activated the
d-pump is running continuously.
There are no possibilities for the drain system to evacuate water
from the bottom tray, so when the d-pump has emptied the tub it
will still drain but without draining any water out: Customer
complaint, not draining?!
Even in this case the Service tech have to locate the leaking point
Leakages:
If the leakage point is located to the d-pump check:
- the two screws holding the d-pump on to the tub.
- the oring between the d-pump / tub (misaligned, distorted) ??
- the housing three screws on the d-pump.
If the leakage point is located to the d-pump check:
- the two screws holding the bracket / circulation pump in place.
- disassemble the circulation pump from the tup and check for
„plastic burr“ in the tub / oring connection.
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Check the locknut under the salt cap
to ensure it is fully tightened.
It should not be possible
to unsrew by hand.
In the case of leakage,
here more checkpoints
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16.
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